Abstract

Passive safety regulations and the latest NCAP protocols increasingly emphasize the protection of commercial vehicle occupants and vulnerable road users. At the same time, the need to reduce development costs is driving truck manufacturers toward a growing reliance on virtual simulation, thereby requiring continuous improvements in its accuracy and reliability. In this context, IVECO is pursuing a structured program aimed at enhancing its numerical simulation capabilities.
The present work originates from this program and focuses on the development of a finite element (FE) model in Abaqus for the characterization of the mechanical behavior of spot weld joints, explicitly accounting for both deformation and failure mechanisms.
Based on experimental force-displacement responses obtained from mechanical tests on welded steel plates, an Abaqus Explicit constitutive and damage modeling framework was assessed. Spot weld material properties and failure parameters were calibrated using the Dassault Systèmes Platform Material Calibration algorithm. The resulting model demonstrates strong predictive accuracy and represents a key enabler for achieving reliable crash simulation results at both sub-system and full-vehicle levels.

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Speaker

Marco Barbi is a Structural Virtual Analyst with more than 25 years of experience in the field of numerical simulation. He obtained a Master's degree in Aerospace Engineering from the Politecnico di Torino in 1998.
Marco began his professional career in consultancy companies as a virtual structural analyst, focusing primarily on crashworthiness and passive safety topics. During this period, he collaborated with major automotive, aeronautical, railway, and industrial companies, contributing to the design and development of safety structures in compliance with relevant regulations and standards.
In 2011, Marco joined lveco S.p.A., where he continued his work as a virtual structural analyst, further expanding his expertise in the passive safety of commercial vehicles. Over the years, he has been involved in projects covering the entire LVECO product range, from light to heavy commercial vehicles and buses, developing an in-depth understanding of vehicle architectures and passive safety systems.
Marco is currently part of the IVECO Vehicle Engineering Performance and Simulation Department, where he works within the Passive Safety Performance and Simulation Team, with responsibility for heavy commercial vehicles.

@MB 
Passive Safety and Structural Senior Analyst, IVECO